European Technical Approval DYWIDAG Post … Technical Approval DYWIDAG Post-Tensioning System using Strands DYWIDAG External Strand Post-Tensioning System for 3 to 37 Strands (140

DYWIDAG Post-TensioningEuropean Technical Approval

DYWIDAG Post-Tensioning System using Strands

DYWIDAG External Strand Post-Tensioning Systemfor 3 to 37 Strands (140 and 150 mm2)

ETA-09/0068

Validity 03 March 2009 - 03 March 2014

European Organisation for Technical ApprovalsEuropäische Organisation für Technische ZulassungenOrganisation Européenne pour l‘Agrément Technique

Le présent ATE contient:

This ETA contains:

45 pages incluant 25 pages d‘annexes (dessins) 45 pages including 25 pages of annexes (drawings)

O r g a n i s a t i o n p o u r l ’ A g r é m e n t T e c h n i q u e E u r o p é e n

E u r o p e a n O r g a n i s a t i o n f o r T e c h n i c a l A p p r o v a l s

Sétra 46, avenue Aristide Briand BP 100 92 225 BAGNEUX CEDEX Tel: + 33 (0)1 46 11 31 31 Fax: + 33 (0)1 46 11 31 69

Member of EOTA

Agrément Technique Européen ETA-09/0068 (version originale en français)

European Technical Approval ETA-09/0068 (original version in French language)

Nom Commercial: Trade name:

Procédé de précontrainte extérieure DYWIDAG DYWIDAG External Strand Post-Tensioning System

Détenteur de l’ATE: ETA Holder:

DYWIDAG-Systems International GmbH Dywidagstrasse 1 85609 Aschheim DEUTSCHLAND

Type générique et utilisation prévue du produit de construction: Generic type and use of construction product:

Procédé de précontrainte par post-tension DYWIDAG avec cable extérieur de 3 à 37 torons (140 et 150 mm²) DYWIDAG External Strand Post-Tensioning System for 3 to 37 Strands (140 and 150 mm²)

Validity: from

03/03/2009

to 03/03/2014

Producteur du Procédé: Manufacturing plant:

DYWIDAG-Systems International GmbH Dywidagstrasse 1 85609 Aschheim DEUTSCHLAND

Page 2 of ETA-09/0068 English translation by Sétra

A LEGAL BASIS AND GENERAL CONDITIONS A.1 This European Technical Approval is issued by Sétra in accordance with: - Council Directive 89/106/EEC of 21 December 1988 on the approximation of

laws, regulations and administrative provisions of Member States relating to construction products1, modified by Council Directive 93/68/EEC2 and Regulation (EC) No 1882/2003 of the European Parliament and the Council3;

- Décret no 92-647 du 8 juillet 1992 4 concernant l’aptitude des produits de construction;

- Common Procedural Rules for Requesting, Preparing and the Granting of European Technical Approvals set out in the Annex to Commission Decision 94/23/EC5;

- ETAG 013, Edition June 2002, Post-Tensioning Kits for Prestressing of Structures.

A.2 Sétra is authorized to check whether the provisions of this European Technical Approval are met. Checking may take place in the manufacturing plant(s). Nevertheless, the responsibility for the conformity of the products to the European Technical Approval and for their fitness for the intended use remains with the holder of the European Technical Approval. A.3 This European Technical Approval is not to be transferred to manufacturers or agents of manufacturers other than those indicated on page 1, or manufacturing plants other than those indicated on page 1 of this European Technical Approval. A.4 This European Technical Approval may be withdrawn by Sétra, in particular pursuant to information by the Commission according to Article 5(1) of Council Directive 89/106/EEC. A.5 Reproduction of this European Technical Approval including transmission by electronic means shall be in full. However, partial reproduction can be made with the written consent of Sétra. In this case partial reproduction has to be designated as such. Texts and drawings of advertising brochures shall not contradict or misuse the European Technical Approval. A.6 The European Technical Approval is issued by the approval body in its official language(s). This version corresponds fully to the version circulated in EOTA. Translations into other languages have to be designated as such.

1 Official Journal of the European Communities No L 40, 11.2.1989, p. 12 2 Official Journal of the European Communities No L 220, 30.8.1993, p. 1 3 Official Journal of the European Union No L 284, 30.10.2003, p. 1 4 JORF du 14 juillet 1992 5 Official Journal of the European Communities No L 17, 20.1.1994, p. 34


B SPECIFIC CONDITIONS OF THE EUROPEAN TECHNICAL APPROVAL

B.1 DEFINITION OF PRODUCTS AND INTENDED USE

B.1.1 Definition of Products This European Technical Approval applies to a kit: DYWIDAG – External Strand Post-Tensioning System consisting of 3 to 37 strands. The DYWIDAG post-tensioning kit is designed for external prestressing. The prestressing tendon consists of a bundle of 7-wire strands, anchorages, deviators, sheathing and corrosion protective compounds.

- The strands are defined in the prEN 10138-3: ”Prestressing steels – Strand” as 0.6” ‘normal’ and ‘super’ strand, i.e. with Ø 15.3 and Ø 15.7 mm nominal diameter, with a nominal tensile strength of 1770 or 1860 N/mm², coded Y1770S7 15.3 (or 15.7) or Y1860S7 15.3 (or 15.7), respectively, referred to as the ‘tensile element’. As long as EN 10138 is not implemented 7-wire strands in accordance with national provisions shall be used.

- Stressing (active) anchorages and fixed (passive) anchorages consisting of

an anchor plate with connection tube, steel trumpet, plastic insert, gasket, retaining ring, spacer and wedge plate.

- Sheathings are made of plastic (polyethylene, HDPE).

- Deviators are specific elements at given locations in the structure along the

tendon. These are generally made of steel tubes (straight or prebent) placed inside the concrete structure or construction steel saddles applied to the structure.

- Bursting reinforcement (helix and stirrups), for the concrete confinement at

anchorages to ensure local prestressing force transfer into the concrete structure.

- The corrosion protecting compound can be a cement based grout (in

accordance with EN 447) for rigid injection or a flexible compound with a wax base (in accordance with Annex C.4.2 of ETAG 013).


Steel and plastic tubes, the ordinary reinforcement for bursting reinforcement, grouting products are covered by European or national provisions thus they are not described in this ETA. However, they can be used for the prestressing kit.

B.1.2 Intended use The DYWIDAG external strand post-tensioning system (in the following PT system) has been developed to be used for

• new structures • repair and strengthening of existing structures

exposed to effects from gravity and live loads, climate exposures, imposed sets of deformations. This PT system is meant for concrete structures/members with a tendon path situated outside their cross section but inside their envelope. It may also be employed in structures made of other materials, e.g. masonry, steel, cast iron, timber or combinations of several materials (see Annex 13). In case of use with other materials than concrete, dimensions and force transfer shall be designed according to the relevant Eurocodes or national regulations valid in place of use. The following optional use categories for the tendons are possible:

• restressable • exchangeable • encapsulated

B.1.3 Working life The provisions made in this European Technical Approval are based on an assumed working life of the PT system of 100 years. These provisions are based upon the current state of the art and the available knowledge and experience. The indications given on the working life cannot be interpreted as a guarantee given by the kit manufacturer or the Approval Body, but are to be regarded only as a means for choosing the right products in relation to the expected economically reasonable working life of the works. The relevant Eurocodes are the following: EN 1990 “Eurocode 0”: Basis of structural design EN 1991 “Eurocode 1”: Actions on structures EN 1992 “Eurocode 2”: Design of concrete structures EN 1993 “Eurocode 3”: Design of steel structures EN 1994 “Eurocode 4”: Design of composite steel and concrete structures EN 1995 “Eurocode 5”: Design of timber structures EN 1996 “Eurocode 6”: Design of masonry structures The PT system is supposed to be subject to appropriate use and maintenance (see Chapter 7 of ETAG 013).


B.2 Characteristics of product and methods of verification

B.2.1 Characteristics of product B.2.1.1 General The components correspond to the drawings and provisions given in this European Technical Approval including the Annexes. The characteristic material values, dimensions and tolerances of the components not indicated in the Annexes shall correspond to the respective values laid down in the technical documentation of this European Technical Approval. Arrangement of the tendons, the design of the anchorage zones, the anchorage components and the diameters of the sheathings shall correspond to the attached description and drawings; the dimensions and materials shall comply with the values given therein.

The first digit of the designation of components of anchorages (6) identifies the nominal strand diameter in tenfold of inches (0.6”/0.62”), the second digit is an internal code and the last two digits refer to the number of strands in the tendon (size of tendon). The components (except helix and additional reinforcement) fit for tendons with both strand strengths. B.2.1.2 Strands Only 7-wire strands shall be used in accordance with national provisions with the characteristics given in Annex 16. To avoid confusions only strands with one nominal diameter shall be used on one site. If the use of strands with Rm = 1860 MPa is intended on site, these shall only be used there. Only strands stranded in the same direction shall be used in a tendon. B.2.1.3 Wedges Wedges (see Annex 2) are approved with 30°-tooth or 45°-tooth. The segments of the wedges for strands ∅ 15.3 mm are 42 mm long and the segments of the wedges for strands ∅ 15.7 mm are 45 mm long. The wedge dimension does not depend from the strands’ strength. Wedges of one supplier only may be used at one construction site. B.2.1.4 Wedge plates The conical drills of the wedge plates (see Annexes 3-5) shall be clean, stainless and provided with a corrosion protection. B.2.1.5 Anchor plate with recess tube Circular anchor plate with recess tube welded watertight to it shall be used (see Annexes 3-5).


B.2.1.6 Steel trumpet with PE-insert As a part of the steel trumpet the tension ring is welded to the steel tube with the flange. The PE-insert is fixed to the tension ring through a gasket with a retaining ring and screws (see Annex 2). A piece of plastic sheathing with relevant diameter is mirror welded to the PE-insert. Its length is determined in order to protrude out from the concrete body around the anchorage zone. B.2.1.7 Bursting reinforcement (helixes and stirrups) The steel grades and dimensions of the helixes and of the stirrups shall comply with the values given in the relevant Annexes 6-11. The central position in the structural concrete member on site shall be ensured according to section B.4.2.3. The outer end of the helix shall be welded to the anchor plate. This is not necessary if the final turn is welded to form a closed ring. B.2.1.8 Sheathings, tubes Sheathings made of polyethylene shall comply with EN 12201 and ETAG 013. The dimensions of the sheathings shall comply with values given in Annex 2. The connections and seals between the sections of sheathing are effected either with mirror welding or electro-welding couplers. The recess tubes and steel tubes (respectively welded to anchor plate and flange, see Annexes 3-5) are manufactured from at least 3.2 mm thick steel sheath material (see Annex 15). B.2.1.9 Grout Grout according to EN 447:1996 shall be used. B.2.1.10 Wax Wax as defined in Annex C.4.2 of ETAG 013 or according to national regulations valid in place of use shall be used. B.2.1.11 Protective caps Protective caps serve as closing the anchorage to enable grouting/injection and its protection, see Annex 12. The caps are made of steel. Regularly they cover the wedge plate and are left in place after injection. Elongated caps may be used for sufficient strand over-length for later prestressing force adjustment or detensioning.


B.2.2 Methods of verification B.2.2.1 General This European Technical Approval for the "DYWIDAG external strand post-tensioning system" is issued on the basis of agreed data, deposited at Sétra, which identifies the "DYWIDAG external strand post-tensioning system" that has been assessed and judged. Assessment of the fitness of the "DYWIDAG external strand post-tensioning system" for the intended use in relation to the requirements for mechanical resistance and stability in the sense of Essential Requirements 1 and for ER3 (hygiene, health and environment) has been made in accordance with the ETAG 013, Guideline for European Technical Approval of post-tensioning kits for prestressing of structures, based on the provisions for all systems. The release of dangerous substances (Essential Requirement 3) is determined according to ETAG 013, clause 5.3.1. A declaration was made by the kit manufacturer that the product does not contain any dangerous substances. In addition to the specific clauses relating to dangerous substances contained in the ETA, there may be other requirements, applicable to the products falling within its scope (e.g. transposed European legislation and national laws, regulations and administrative provisions). In conformity with the provisions of the European directive 89/106/EEC, these requirements must also be complied with wherever they apply. The structural members (made of normal-weight concrete) prestressed by means of the DYWIDAG-External Strand Post-Tensioning System used to be designed in accordance with national regulations. B.2.2.2 Tendons The maximum prestressing and over-tensioning force to be applied on the tendon is specified in the national standards and regulations in force in the place of use. The maximum force P0, max defined according to EN 1992-1-1 paragraph 5.10.2 (with recommended values for k1 and k2), and according to prEN 10138, shall not exceed the values laid down in Table 1 (140 mm²) or in Table 2 (150 mm²). Maximum prestressing force P0, max = min (0.8 Fpk ; 0.9 Fp0.1k) where Fpk = Ap fpk is the characteristic tensile force of tensile elements of tendons and Fp0.1k = Ap fp0.1k the characteristic tensile yield force of tensile elements of tendon (0.1 % proof load). The initial prestressing force Pm0 immediately after tensioning and anchoring shall not exceed the values laid down in Table 1 (140 mm²) or in Table 2 (150 mm²), see also Annex 1. Initial prestressing force Pm0 = min (0.75 Fpk ; 0.85 Fp0.1k)


Table 1: Maximum prestressing forces6 for tendons with Ap = 140 mm²

Tendon Designation

Number of

strands

Cross section

Ap [mm²]

Prestressing force Y1770S7

Fp0.1k = 218 kN Prestressing force

Y1860S7 Fp0.1k = 229 kN

Pm0, max [kN] P0, max [kN] Pm0, max [kN] P0, max [kN]

6803 3 420 556 589 584 618 6804 4 560 741 785 779 824 6805 5 700 927 981 974 1031 6807 7 980 1297 1373 1363 1443 6809 9 1260 1668 1766 1752 1855 6812 12 1680 2224 2354 2336 2473 6815 15 2100 2780 2943 2921 3092 6819 19 2660 3521 3728 3699 3916 6822 22 3080 4077 4316 4283 4534 6827 27 3780 5003 5297 5257 5565 6831 31 4340 5744 6082 6036 6389 6837 37 5180 6856 7259 7204 7626

Table 2: Maximum prestressing forces6 for tendons with Ap = 150 mm²

Tendon Designation

Number of

strands

Cross section

Ap [mm²]


Fp0.1k = 234 kN


Fp0.1k = 246 kN Pm0, max [kN] P0, max [kN] Pm0, max [kN] P0, max [kN]

6803 3 450 597 632 627 664 6804 4 600 796 842 836 886 6805 5 750 995 1053 1046 1107 6807 7 1050 1392 1474 1464 1550 6809 9 1350 1790 1895 1882 1993 6812 12 1800 2387 2527 2509 2657 6815 15 2250 2984 3159 3137 3321 6819 19 2850 3779 4001 3973 4207 6822 22 3300 4376 4633 4600 4871 6827 27 4050 5370 5686 5646 5978 6831 31 4650 6166 6529 6482 6863 6837 37 5550 7359 7792 7737 8192

6 The forces P0, max and Pm0 are given as indicative values. The actual values are to be found in national

regulations valid on place of use. Compliance with the stabilisation and crack width criteria in the load transfer test was verified to a load level of 0.80 Fpk.


The number of strands in a tendon may be reduced by leaving out strands lying radial-symmetrically in the wedge plate. The provisions for tendons with completely filled wedge plates (basic types) also apply to tendons with only partly filled wedge plates. Into the cones not filled short pieces of strands with wedges have to be pressed to assure a sufficient bending stiffness of the wedge plate. Obviously for such tendons wedge plates machined without the not needed conical borings can be applied, too. The prestressing force is reduced per strand left out as shown in Table 3. Table 3: Reduction of the prestressing force when leaving out one strand

Ap Y1770S7 Y1860S7 ∆Pm0 [kN] ∆P0 [kN] ∆Pm0 [kN] ∆P0 [kN]

140 mm² 185.3 196.2 194.7 206.1 150 mm² 198.9 210.6 209.1 221.4

B.2.2.3 Losses of the prestressing force due to friction At calculation the losses of the prestressing force due to friction the friction coefficient µ = 0.12 – 0.14 shall be considered. This value is for information only. The exact friction coefficient must be adapted to each project and also in case of restressing. At external tendons no wobble coefficient k (unintentional deviation) need to be taken into account. For the determination of strains and forces of prestressing steel friction losses ΔPµA in the active anchorage zone shall be taken into account as follows:

- For the tendon sizes from 6803 to 6805: ΔPµA = 1.0 % - For the tendon sizes from 6807 to 6837: ΔPµA = 0.5 %


B.2.2.4 Radius of curvature of the tendons at deviations and geometry of deviators The smallest admissible radius of curvature of the tendons with sheathings as defined in Appendix C.2 of ETAG 013 based on ENV 1992-1-5 and the required dimensions of the bent steel deviation tubes are given in Table 4 and Annex 14. Table 4: Smallest radius of curvature of deviators

Tendon Min. radius of curvature


6803 2.00 m 6815 2.75 m

6804 2.00 m 6819 3.00 m

6805 2.00 m 6822 3.25 m

6807 2.00 m 6827 3.50 m

6809 2.25 m 6831 3.75 m

6812 2.50 m 6837 4.00 m

The minimum values of radius of curvature given in Table 4 shall be respected, unless a national regulation is stricter. Smooth steel pipes can be bent to a constant radius in one plane. This should be taken into account at when specifying the tendon layout. Behind the anchor plate a straight length of the tendon (measured form the top of the anchor plate) according to Table 5 is required. Table 5: Required straight length of the tendon in the anchorage zone (measured

from the top of the anchor plate)

Tendon Straight length of the tendon

Tendon Straight length of the tendon

6803 0.70 m 6815 1.20 m

6804 0.80 m 6819 1.30 m

6805 0.85 m 6822 1.40 m

6807 0.90 m 6827 1.50 m

6809 1.00 m 6831 1.60 m

6812 1.10 m 6837 1.60 m

In case of an exchangeable tendon with cement grout no curved tendon layout is allowed within the concrete body around the anchorage zone.


In case of a curved tendon layout in the anchorage zone, the smallest admissible radius of curvature is given in Table 6. Table 6: Smallest radius of curvature of deviators behind the anchorage


behind anchorage


behind anchorage

6803 3.00 m 6815 3.75 m

6804 3.00 m 6819 4.00 m

6805 3.00 m 6822 4.25 m

6807 3.00 m 6827 4.50 m

6809 3.25 m 6831 4.75 m

6812 3.50 m 6837 5.00 m

The minimum values of radius of curvature given in Table 6 shall be respected, unless a national regulation is stricter. B.2.2.5 Concrete strength At the time of transmission of the full prestressing force to the concrete member the mean concrete strength in the anchorage zone shall be at least fcmj, cube or fcmj, cyl according to Table 7. The mean concrete strength (fcmj, cube or fcmj, cyl) shall be verified by means of at least three specimens (cube with the edge length of 150 mm or cylinder with diameter of 150 mm and height of 300 mm), which shall be stored under the same conditions as the concrete member, with the individual values of specimens not differ more than 5 %. Table 7: Necessary minimum mean concrete strength fcmj of the specimens at time

of prestressing

fcmj, cube [N/mm²] fcmj, cyl [N/mm²]

25 20

45 36

60 50 For partial prestressing with 30 % of the full prestressing force the actual mean value of the concrete compressive strength to be proved is 0.5 fcmj, cube or 0.5 fcmj, cyl; intermediate values may be interpolated linearly.


B.2.2.6 Centre and edge distances of the tendon anchorages, concrete cover The centre and edge distances of the tendon anchorages shall be the values given in the Annexes 6-11 depending on the actual mean concrete strength. The values of the centre or edge distances of the anchorages given in the Annexes may be reduced in one direction up to 15 %, however, not to a smaller value than the external diameter of the helix plus 20 mm (see Annexes 6-11). The centre or edge distances of the anchorages in the other direction shall be increased for keeping the same concrete area in the anchorage zone. The dimensions of the additional reinforcement shall be fitted accordingly. All centre and edge distances have only been specified in conjunction with load transfer to the structure; therefore, the concrete cover given in national standards and provisions shall be taken into account additionally. The concrete cover may under no circumstance be less than 20 mm or smaller than the concrete cover of the reinforcement installed in the same cross section. The concrete cover of the anchorage should be at least 20 mm. Standards and regulations on concrete cover valid in place of use shall be considered. B.2.2.7 Reinforcement in the anchorage zone The anchorages (including reinforcement) for the transfer of the prestressing forces to the structural concrete were verified by means of tests. The resistance to the forces occurring in the structural concrete in the anchorage zone outside the helix and the additional reinforcement shall be verified. An adequate transverse reinforcement shall be provided here in particular for the occurring transverse tensile forces (not shown in the attached drawings). The steel grades and dimensions of the additional reinforcement (stirrups) shall follow the values given in the Annexes 6-11. From the given amount of additional reinforcement 50 kg reinforcement steel/m³ concrete may be taken into account as part of the statically required reinforcement. Existing reinforcement in a corresponding position more than the reinforcement required by design may be taken into account for the additional reinforcement. The additional reinforcement shall be of closed stirrups (stirrups closed by means of bends or hooks or an equivalent method) or of orthogonal reinforcement properly anchored. The stirrups locks (bends or hooks) shall be placed staggered. In the anchorage zone vertically led gaps shall be provided for proper concreting. If required for a specific project design, the reinforcement given in the Annexes can be modified in accordance with the respective regulations in force at the place of use as well as with relevant approval of the local authority and of the ETA holder to provide equivalent performance. If in exceptional cases 7 – due to an increased amount of reinforcement – the helix or the concrete cannot be properly placed, the helix can be replaced by different equivalent reinforcement. B.2.2.8 Slip at the anchorages The slip at the anchorages (see section B.4.2.4) shall be taken into account in the static calculation and the determination of the tendon elongation.

7 This requires the approval of the local authority for individual case according to the national regulations

and administrative provisions.


B.3 Evaluation and attestation of conformity and CE marking

B.3.1 System of attestation of conformity According to the decision 98/456/EC of the European Commission8 the system 1+ of attestation of conformity applies. This system of attestation of conformity is defined as follows: System 1+: Certification of the conformity of the product by an approved certification

body on the basis of: (a) Tasks of the kit manufacturer:

(1) Factory production control, (2) Further testing of samples taken at the factory by the kit manufacturer in

accordance with a prescribed test plan. (b) Tasks for the approved body:

(3) Initial type-testing of the product, (4) Initial inspection of factory and of factory production control, (5) Continuous surveillance, assessment and approval of factory

production control, (6) Audit-testing of samples taken at the kit manufacturer.

B.3.2 Responsibilities B.3.2.1 Tasks of the kit manufacturer B.3.2.1.1 Factory production control The kit manufacturer shall keep available an updated list of all components manufacturers. The list is provided to the Certification Body and to the Approval Body. The kit manufacturer shall exercise permanent internal control of production. All the elements, requirements and provisions adopted by the kit manufacturer shall be documented in a systematic manner in the form of written policies and procedures, including records of results performed. This production control system shall insure that the product is in conformity with this European Technical Approval. The kit manufacturer may only use initial materials stated in the technical documentation of this European Technical Approval. The factory production control shall be in accordance with the "Control Plan of 27 January 2009 relating to the European Technical Approval ETA-09/0068 issued on 03 March 2009" which is part of the technical documentation of this European Technical Approval. The "Control Plan" is laid down in the context of the factory production control system operated by the kit manufacturer and deposited at Sétra9.

8 Official Journal of the European Communities No L 201/112, 3.7.1998 9 The "control plan" is a confidential part of the European Technical Approval and only handed over to

the approved body involved in the procedure of attestation of conformity. See section 3.2.2.


The prescribed test plan defined in Annex 17 gives the type and frequency of checks and tests conducted during production and on the final product as part of the continuous internal production control. The results of factory production control shall be recorded and evaluated in accordance with the provisions of the "Control Plan". The records shall contain at least the following information:

- Designation of the product or the initial material and the components, - Kind of control or testing, - Date of manufacture and of testing of product or components and of initial

material, - Results of controls and tests and, where specified, comparison with the

requirements, - Name and signature of person responsible for the factory production control.

The records shall be kept for at least ten years and on request they shall be presented to Sétra. If the test results are not satisfactory, the kit manufacturer shall take immediate measures to eliminate defects. Construction products or components which are not in compliance with the requirements shall be handled such that they can not be mistaken for products complying with the requirements. After elimination of the defects the relevant test shall be immediately repeated as far as is technically possible and necessary for verifying the deficiency elimination. B.3.2.1.2 Other tasks of kit manufacturer The kit manufacturer shall, on the basis of a contract, involve a body which is approved for the tasks referred to in section B.3.1 in the field of Post-Tensioning Kits for Prestressing of Structures in order to undertake the actions laid down in section B.3.3. For this purpose, the "control plan" referred to in sections B.3.2.1.1 and B.3.2.2 shall be handed over by the kit manufacturer to the approved body involved. The kit manufacturer shall make a declaration of conformity, stating that the construction product is in conformity with the provisions of the European Technical Approval ETA-09/0068 issued on 03 March 2009. At least once a year, each components manufacturer shall be audited by the kit manufacturer. At least once a year specimens shall be taken from one job site and one series of single tensile element tests shall be performed according to ETAG 013, Annex E3 (see Annex 18). The results of these test series shall be made available to the approved body.


B.3.2.2 Tasks of the approved body B.3.2.2.1 General The approved body shall perform the

- initial type-testing of the product, - initial inspection of factory and of factory production control, - continuous surveillance, assessment and approval of factory production

control, - audit-testing of samples taken at the factory

in accordance with the provisions laid down in the "Control Plan of 27 January 2009 relating to the European Technical Approval ETA-09/0068 issued on 03 March 2009". The approved body shall retain the essential points of its actions referred to above and state the results obtained and conclusions drawn in a written report. The main production centre is checked at least once a year by the approved body. Each component producer is checked at least once every five years by the approved body. The approved certification body involved by the kit manufacturer (DYWIDAG-Systems International GmbH) shall issue an EC certificate of conformity of the product stating the conformity with the provisions of this European Technical Approval. In cases where the provisions of the European Technical Approval and its "Control Plan" are no longer fulfilled the certification body shall withdraw the certificate of conformity and inform Sétra without delay. B.3.2.2.2 Initial type-testing of the product For initial type-testing the results of the tests performed as part of the assessment for the European Technical Approval may be used unless there are changes in the production line or plant. In such cases the necessary initial type-testing has to be agreed between Sétra and the approved body involved. B.3.2.2.3 Initial inspection of factory and of factory production control The approved body shall ascertain that, in accordance with the "Control Plan”, the factory, in particular the staff and equipment, and the factory production control are suitable to ensure a continuous and orderly manufacturing of the PT system with the specifications mentioned in section B.2.1 as well as in the Annexes to the European Technical Approval. B.3.2.2.4 Continuous surveillance, assessment and approval of factory production

control The kit manufacturer shall be inspected by the approved body at least once a year. Each component manufacturer shall be inspected at least once in five years. It shall be verified that the system of factory production control and the specified manufacturing process are maintained taking account of the prescribed test plan.


Continuous surveillance and assessment of factory production control have to be performed according to the prescribed test plan. The results of product certification and continuous surveillance shall be made available on demand by the approved body to Sétra. B.3.2.2.5 Audit-testing of samples taken at the kit manufacturer During surveillance inspections the approved body shall take samples at the factory of components of the PT system or of individual components for which this Technical Approval has been granted, for independent testing. For the most important components Annex 17 contains the minimum procedures which have to be performed by the approved body. The basic elements of the Audit testing comply with ETAG 013, Annex E2 (see Annex 18). B.3.3 CE marking CE marking is in accordance with the Construction Products Directive and the Guidance Paper “D” (EC/OEAT 04/645 Document). The CE marking shall be affixed on the delivery note. The letters "CE" shall be followed by the identification number of the Approved Certification Body, where relevant, and shall be accompanied by the following additional information:

- The name or identifying mark of the kit manufacturer and of the production plant (legal entity responsible for the manufacture),

- the last two digits of the year in which the CE marking was affixed, - the number of the CE certificate of conformity for the product, - the number of the European Technical Approval, - the category(ies) of use (trade name).

B.4 Assumptions under which the fitness of the product for the intended use was favourably assessed

B.4.1 Manufacturing The European Technical Approval is issued for the product on the basis of agreed data/information, deposited with Sétra, which identifies the product that has been assessed and judged. Changes to the product or production process, which could result in this deposited data/information being incorrect, should be notified to Sétra before the changes are introduced. Sétra will decide whether or not such changes affect the ETA and consequently the validity of the CE marking on the basis of the ETA and if so whether further assessment or alterations to the ETA shall be necessary.


B.4.2 Installation B.4.2.1 General Assembly and installation of the tendons shall only be performed by qualified post-tensioning specialist companies which have the required technical skills and experiences with this DYWIDAG PT system. The company’s site manager shall have a certificate of the ETA holder certifying that he is instructed by the ETA holder and has the required knowledge and experience with this PT system. National standards and regulations valid on site shall be considered. The ETA holder is responsible to inform anyone concerned about the use of this DYWIDAG PT system. Additional information as listed in ETAG 013, section 9.2 shall be held available at the ETA holder and shall be distributed as needed. The tendons and the components shall be handled carefully. B.4.2.2 Welding Welding at the anchorages is only permitted at the following points: a) Welding of the end of the helix to a closed ring. b) For ensuring the central position the helix may be attached to the anchor plate

by welding. After mounting the tendons no more welding shall be performed at the anchorages and in the immediate vicinity of the tendons. B.4.2.3 Installation of the tendon The central position of the helix and stirrups shall be ensured by tack-welding to the anchor plate or other appropriate mountings. The anchor plate shall be in direction perpendicular to the axis of the straight tendon in the vicinity of the anchorage.

The tendon shall be placed straightforward behind the anchorage according to Table 5.

B.4.2.4 Wedging force, slip at anchorages, wedge securing and corrosion protection compound

If the calculated prestressing force is less than 0.7 Pm0, max the wedges of fixed anchorages shall be pre-wedged with P0, max (see section B.2.2.2).

The draw-in of the anchorage to be taken into account for the determination of the elongations and at load transfer from the jack onto the anchorage shall be taken from Table 8.

The wedges of all anchorages (fixed anchorages) which are no more accessible during tensioning shall be secured by means of wedge keeper plates and bolts.


Table 8: Draw-in values for calculation of elongation [mm]

Draw-in at stressing anchorage Draw-in at fixed anchorage

Draw-in to be considered for calculation of

elongation

Draw-in at load transfer from the jack onto

the anchorage

Draw-in to be considered for calculation of elongation

Without pre-wedging or power-seating 1 8 6

With power-seating 20 kN per strand at stressing anchorage 1 4 -

With pre-wedging P0, max at fixed anchorage - - 1

At installation of the wedges into the conical borings of the not accessible fixed anchorages the gaps shall be filled with corrosion protection compound. Before pouring of concrete the wedge plates of the not accessible fixed anchorages shall be sealed with a grout cap. B.4.2.5 Stressing and stressing records B.4.2.5.1 Stressing At time of stressing the minimum mean concrete strength shall comply with the values given in section B.2.2.5. In the vicinity of the anchor plates the concrete must be especially homogeneous. It is admissible to restress the tendons by releasing and re-using the wedges. After restressing and anchoring, wedge marks on strands resulting from first stressing shall be moved to the outside by at least 15 mm. The minimum straight length for tensioning behind the anchorages (strand protrusion) depends on the jack which is used on site (see Annex 20). All strands of a tendon shall be stressed simultaneously. This can be done by centrally controlled individual jacks or by a bundle jack. B.4.2.5.2 Stressing record All stressing operations shall be recorded for each tendon. In general, the required prestressing force shall be achieved. The elongation is measured and compared with the calculated value. If during tensioning the difference between measured and calculated elongation is more than 15 % of the calculated value then the engineer shall be informed and the causes shall be found.


B.4.2.5.3 Prestressing jacks and space requirements, safety-at-work For stressing hydraulic jacks are used. Information about the stressing equipment is shown in Annex 20. To facilitate jack placement and stressing the tendons, clearance according to Annex 21 shall be considered directly behind the anchorages. The safety-at-work and health protection regulations shall be complied with. B.4.2.6 Grouting B.4.2.6.1 Grout and grouting procedures Grout according section B.2.1.9 shall be used. Grouting procedures shall be carried out in accordance with EN 446:1996. Local standards and national regulations valid in place of use shall be considered. B.4.2.6.2 Water rinse Normally, sheathing shall not be rinsed with water. Local standards and national regulations valid in place of use shall be considered. B.4.2.6.3 Grouting speed The grouting speed shall be in the range between 3 m/min and 12 m/min. B.4.2.6.4 Grouted section and re-grouting The length of a grouted section shall not exceed 120 m for tendons with 3 to 22 strands, 95 m for tendons with 23 to 27 strands and 50 m for tendons with 28 to 37 strands. When exceeding these tendon lengths, additional grouting openings shall be provided. Where the tendon is led via distinct high points, re-groutings shall be performed in order to avoid voids. For re-groutings corresponding measures shall be taken into account already in design. Vents on the ducts shall be provided at both ends and at the points of the tendon where air or water may accumulate. In case of ducts of considerable length, vents or inlets may be required at intermediate positions. Local standards and national regulations valid in place of use shall be considered. B.4.2.6.5 Surveillance Surveillance according to EN 446:1996 shall be carried out. B.4.2.7 Wax injection B.4.2.7.1 Wax and injection procedures Wax according section B.2.10 shall be used. Injection shall be carried out according to DSI special instructions. Injection equipment is normally composed of melting device (heater), stirrer and pump.


B.5 Packaging, transport and storage

The components and the tendons shall be protected against moisture and staining. The tendons shall be kept away from areas where welding procedures are performed. For strands the smallest diameter of curvature during transport is 1.65 m. The PE-tubes are delivered as straight or prebent tubes for the deviation zones and are connected on site by mirror welding or electro welding couplers.

CONTENT OF CONTROL PLAN

Component

Item

Test/Check

Traceability 5

Minimum frequency

Documentation

Anchor plate

material

check

bulk

100 %

”2.2“ 1

detailed dimensions 6

test 3 % ≥ 2 specimens

yes

visual inspection 4

check 100 % no

Wedge plate

material

check

full

100 %

”3.1“ 2



yes

visual inspection 4

check 100 % no

Steel trumpet

material

check

bulk

100 %

“2.1“ 3



yes

visual inspection 4

check 100 % no

PE-insert

material

check

bulk

100 %

”2.1“ 3



yes

visual inspection 4

check 100 % no

Wedge

material

check

full

100 %

”3.1“ 2

treatment, hardness

test 0.5 % ≥ 2 specimens

yes



yes

visual inspection 4

check 100 % no

Sheathing

material

check

“CE”

100 %

“CE”

visual inspection 4

check 100 % no

Continuation of Control Plan and footnotes see Annex 17b

CONTENT OF CONTROL PLAN - CONTINUED -

Component

Item

Test/Check

Traceability 5

Minimum frequency

Documentation

Tensile element strand

material 7

check

full

100 %

yes

diameter test each coil/bundle

no

visual inspection 4

check each coil/bundle

no

Helix material check full 100 % yes

visual inspection 4

check 100 % no

Stirrups material check full 100 % yes

visual inspection 4

check 100 % no

Constituents of filling material as per EN 447

cement check full 100 % yes

admixtures, additives

check full 100 % yes

Wax

material 8

check

full

100 %

”2.2“ 1 All samples shall be randomly selected and clearly identified. 1 ”2.2“: Test report type ”2.2“, according to EN 10204 2 ”3.1“: Inspection certificate type ”3.1“, according to EN 10204 3 ”2.1“: Declaration of compliance with the order type ”2.1“, according to EN 10204 4 Visual inspection means e.g.: Main dimensions, gauge testing, correct marking or

labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion, coating, etc., as given in the Inspection sheet

5 Full: Full traceability of each component to its raw material Bulk: Traceability of each delivery of components to a defined point 6 Detailed dimensions mean measuring of all dimensions and angles according to the

specification as given in the Inspection sheet 7 Characteristic material properties see Annex 16 8 Characteristic material properties shall comply with ETAG 013, Annex C 4.2.

Component

Item

Test/Check 1

Sampling – Number of

components per audit

Wedge plate

material according to specification

check, test

1

detailed dimensions

test

visual inspection 2

check

Wedge

material according to specification

check, test

2

treatment

test

2

detailed dimensions

test

1

main dimensions, surface hardness

test

5

visual inspection 2

check

5

Single tensile element test

ETAG 013, Annex E.3

test

1 series

Inclined Tube test

ETAG 013, C.4.3.3.2.1

test

1 test

1 All samples shall be randomly selected and clearly identified. 2 Visual inspection means e.g.: main dimensions, gauge testing, correct

marking or labelling, appropriate performance, surface, fins, kinks, smoothness, corrosion, coating, etc., as given in the Inspection sheet.

1 Manufacture

The setup of the DYWIDAG external strand post-tensioning tendon withdeviations can be manufactured in structure itself. At pushing of the strandsand during stressing the sheathing should be fixed against movement. In case of straight tendons partly prefabrication is possible. In this case thesheathing with the steel trumpet of one anchorage can be preassembled inshop or on site. If also the strands are preassembled then they must beprewedged and secured with a wedge keeper plate during transport. For theproper diameter of coil during transport must be considered.

2 Strands used The strands made of high-strength prestressing steel composing the tendonsare defined in the draft European Standard “prEN 10138-3: Prestressing steels– Part 3: Strand” or in national approvals. The primary characteristics are given in Annex 16.

3 Sheathing The sheathing is assembled from PE-tubes as characterized in Annex 2. Thesheathing produced must be mechanically resistant, continuous in shape,ensure continuity of the seal, and UV-resistant, if required in the project’sspecification. The fitting between the sheathing segments is produced by means of mirrorwelding or electro-welding couplers. The sheathing can be prefabricated to itscomplete length or manufactured in the structure. The sheathing is connected to the PE-insert (or its proper extension) of theanchorage by means of mirror welding or electro-welding coupler. To compensate differences between the planned and the actual length of atendon and to compensate unexpected or not avoidable sliding of thesheathing when stressing the tendon at least one telescopic tube should beassembled along the free length near to the stressing anchorage.

4 Inlets, bleed vents and outlets Grouting with cement grout presupposes the possibility of intervening alongthe tendon path in order to adjust the filling and bleed any air, water, etc. thatmay be within the sheathing. In this aim, accessories (electro-welding collarsor welded pipes) for reinjection, venting and bleeding are installed in properpositions on the sheathing. In case of wax injection proper accessories asinlets and for venting shall be applied at proper positions. In case of an injection or vent tube in the region of a deviator this requiredspace has to be considered when planning/dimensioning and manufacturingthe deviators, for example made of prebent steel tubes.

5 Anchorages

Anchorages depending on the tendon sizes are identical for both strand sizesand strand steel grades. The anchorage consists of

- anchor plate with a steel recess tube welded watertight on it, - steel trumpet, consisting of a steel flange, a steel tube and a steel

tension ring welded to its two opposite ends and a PE-insert fixed tothe tension ring with a retaining ring through a gasket and screws. Ifnecessary, a piece of PE-sheathing of proper length is mirror-weldedto the PE-insert in order to overhang the concrete member backsidethe anchorage and make a connection with the ordinary sheathingpossible,

- spacer within the steel trumpet which puts the strands in order andguarantees a proper fatigue strength and improves the wedge plateplacing,

- wedge plate, - wedges.

The anchor plate can be concrete-encased or placed onto the structurewhereas the continuous and uniform support of the anchor plate must beguaranteed. This type of anchorage can likewise be used as stressing and accessible fixed(passive) anchorage – and with a wedge keeper plate as not accessible. Thewedges of the embedded passive anchorage have to be sealed. Stressing anchorages can be restressed. In order to unload the tendon beforegrouting and to restress after grouting, shims divided into two halves shall bepositioned between flange and anchor plate. Altogether four sets of shims canbe applied at one anchorage. The cuts between the two half-shims shall bestaggered by turning 90°. The bursting forces caused by the prestressing force transfer to the concretemember shall be carried by a helix made of plain steel wire or reinforcementsteel. Additional reinforcement such as straight bars or stirrups is also required In any case the tendon layout in the back of the anchorage shall be straight atleast as long as mentioned in Table 5. If the steel trumpet with PE-insert andonwelded first part of PE-sheathing is installed before concreting of thestructure then even a part of the onwelded piece of PE-sheathing can becurved, whereas the required straight part according to Table 5 and theminimum admissible radius of curvature according to Table 6 shall be obeyed.The requirements of mirror-welding shall be considered. Important is that thecurved parts of the PE-sheathing must be completely and properly supportedby the concrete structure and the deviation tube in the anchorage zone inorder to minimize the bending action effects in the sheathing!

6 Wedges

The wedges are manufactured of alloyed steel for cementation then saw cutinto three parts and then treated. Three segments are attached by means of aretaining ring.

7 Deviators Normally, deviators are made of smooth steel tubes bent in the planned form.Other deviation saddle designs like a curved concrete surface are alsopossible as long as the limits of geometry according to Table 4 and Annex 14are obeyed.

8 Protective caps

In order to enable grouting/injection corrosion protective compound and forfinal protection of the anchorage a permanent metallic cap fixed onto theanchor plate shall be used. The length of the cap shall be determineddepending on, whether the tendon is restressable or not.

9 Stressing A hydraulic pump unit and a centre hole jack are used for stressing theprestressing steel. During stressing all pertinent safety rules andrecommendations must be fully known and obeyed. The force targets alongwith the corresponding values of elongation; moreover, tolerances must beknown. Furthermore, the order in which the post-tensioning tendons are to bestressed must be specified. The required/specified strength of concrete of boththe structure and anchorage zone undergoing stressing must be verified. The strands pass through the jack and are anchored in the tension disk withclamping jaws. All strands of a tendon are stressed simultaneously. Strands ofstraight tendons can be stressed one-by-one with monojacks. The prestressing force is checked with the aid of a pressure gauge.Furthermore, the elongation of the prestressing steel serves as control of theprestressing force. Long tendons for which the jack stroke is insufficient can bestressed in stages. Stressing in load steps and resetting of the jack is easily done. After stressing,the wedges are power seated by means of a seating device within the jack. Awedge slip according to Table 8 remains after wedge seating procedure.

10 Grouting with cement mortar After stressing cement grout can be injected – if specified by the designer –into the void between prestressing steel and sheathing thus serving ascorrosion protection of the strands. Before grouting it shall be controlled that the stressed tendon does not kink atthe ends of the deviations.

The grout is injected through the properly placed grout inlets (mostly at thedeepest points of the sheathing). The sheathing is vented at the ends of the tendon by means of venting pipesor grouting caps. Intermediate venting points at high points are necessary in case of longtendons. The DSI grouting equipment is composed of mixer and pump. For someapplications, vacuum pumps that allows for certain rate of depressurisationinside the sheathing, hence facilitating progression of the grouting (vacuumsupported grouting). Grouting shall be executed in accordance with EN 445, EN 446 and EN 447and national regulations, if applicable. The climatic conditions and temperatureof the structure must satisfy use conditions of the injection product. In case of restressable tendons the strands projecting ends in the cap shall becovered just after grout has been set the grout shall be removed between andon the projecting ends of the strands and singular tubes filled with corrosionprotecting compound shall be slid on. Before the surfaces of wedge plate andwedges shall be covered with corrosion protective tape. The ends of the tubesshall be tightened at the wedge plate with tape. The wedge plate shall becovered with tape. At the other end of the singular tubes these shall be closedwith small caps. Just after grouting the completeness of the filling grade shall be controlled withstrokes of a hammer.

11 Injection Injection products with a wax base as defined in Annex C.4.2 of the ETAG 013shall be used. Before and during injection the relevant prescriptions and requirements of DSImust be obeyed.

Usage of jacks for tendons 68 .. Jack type 01 02 03 04 05 06 07 08 09 10 12 15 19 22 27 31 37

SM 240 ● HoZ 950/100 ● ● ● HoZ 1,700/150 ● ● ● HoZ 3,000/250 ● ● ● ● HoZ 5,400/250 ● ● ● 6,800 ● ● 9,750 ● ●

Jack type 1

Length L Diameter D Stroke Piston area Capacity 2 Weight[mm] [mm] [mm] [cm²] [kN] [kg]

SM 240 842 98 200 47.13 240 19

HoZ 950/100 621 203 100 161.98 972 65

HoZ 1,700/150 803 280 150 298.45 1,745 160

HoZ 3,000/250 1,137 385 250 508.94 3,054 400

HoZ 5,400/250 1,271 482 250 894.57 5,367 600

6,800 1,150 560 300 1237.01 6,803 1,185

9,750 1,170 680 300 1772.45 9,748 1,770

1 Power seating incl. 2 Without friction

BLOCK-OUT-DIMENSIONS [mm]

Jack type A B C D E F G H K L 2

SM 240 880 1 370 - 80 100 75 50 120 100 230/270

HoZ 950/100 621 350 150 - 220 200 130 190 260 300/400

HoZ 1,700/150 803 490 180 - 270 230 170 220 340 450/600

HoZ 3,000/250 1,130 650 220 300 360 320 220 310 440 350/600

HoZ 5,400/250 1,235 740 220 300 420 360 270 320 540 450/800

6,800 1,421 1 - 80 - - 330 310 410 620 - /1,200

9,750 1,470 1 - 120 - - 380 390 550 740 - /1,200

1 Stroke incl. 2 Nec. Strand protrusion (without/with power seating device)

A u s t r i A

A r g e n t i n A

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www.dywidag-systems.com

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Documents

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